Continuous Position Sensing for Pneumatic Cylinder Applications

Position sensing for applications involving pneumatic cylinders can be broadly categorized into two types: discrete position sensing and continuous position sensing. 

Discrete position sensing, which for the purposes of this article we’ll refer to as end-of-stroke sensing, is very common.  End-of-stroke sensing involves employing sensors that detect when a pneumatic cylinder has reached the extents of its physical travel (extended or retracted).

But the focus of this article will be continuous position sensing in pneumatic cylinder applications.  Continuous position sensing enables real-time monitoring of the cylinder’s position throughout its entire stroke.  This capability unlocks a wide range of applications and use cases across many industries.  Here are some key examples:

Industrial Automation

• Robotic Assembly Lines: Ensures precise control of actuator positions for tasks like pressing, clamping, or aligning components.

• Pick-and-Place Systems: Allows dynamic adjustment of cylinder positions for handling objects of varying sizes or shapes.

• Packaging Machinery: Enables adaptive control for sealing, cutting, or folding operations based on product dimensions.

Material Handling

• Conveyor Systems: Position feedback helps synchronize pneumatic actuators with conveyor movement for sorting or diverting items.

• Lift Tables and Scissor Lifts: Provides accurate height control for ergonomic positioning or automated stacking.

Automotive Manufacturing

• Welding Fixtures: Ensures repeatable positioning of parts for robotic welding.

• Door and Hood Testing: Simulates opening/closing cycles with precise control for durability testing.

Process Control

• Valve Actuation: Monitors and adjusts valve positions in real-time for fluid or gas flow regulation.

• Pressurized Systems: Maintains consistent force or displacement in applications like pressing or forming.

Conclusion

Choosing between continuous and discrete position sensing for pneumatic cylinders depends on the specific needs of your application. While discrete sensing offers a cost-effective and straightforward solution for basic motion control, continuous sensing provides the precision, flexibility, and diagnostic capabilities required for advanced automation and smart manufacturing. As industries move toward data-driven operations and predictive maintenance, the long-term value of continuous sensing—especially when paired with technologies like IO-Link—can far outweigh its initial investment. Understanding these trade-offs empowers engineers and decision-makers to design systems that balance performance, reliability, and cost efficiency.